Composite Shear Panel for Vehicle Floor
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Solution Overview
Problem
Existing composite material solutions for mass transit vehicles fail to meet market demands for versatile vehicle lengths and performance standards due to high tooling expenses and structural weaknesses, leading to limited appeal and durability issues.
Innovation Solution
A structural shear panel composed of fiber-reinforced materials with a core layer, designed to provide strength and resistance to bending, which can be adapted to various lengths and integrated with a metal chassis to reduce weight and part count, while avoiding high-stress interfaces that cause premature failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If composite materials are used to form vehicle bodies, then weight is reduced and corrosion resistance is improved, but structural strength and durability are compromised
Solution Approach 1:
The patent applies composite materials by combining fiber-reinforced plastic sheets with a foam core to create a sandwich panel structure. This composite construction reduces vehicle weight while maintaining structural integrity through the synergistic combination of materials: the fiber-reinforced sheets provide tensile strength, the foam core provides compressive strength and rigidity, and together they achieve both weight reduction and durable strength.
2Adaptability or versatility
If multiple molds are used to create different vehicle lengths, then adaptability to market demands is improved, but tooling expenses increase significantly
Solution Approach 1:
The patent applies segmentation by dividing the vehicle body into modular sections that can be assembled in different configurations. The body is constructed from standardized panels and structural components that can be combined to create various vehicle lengths, eliminating the need for multiple complete molds while maintaining adaptability to different market requirements.
Solution Approach 2:
The patent applies universality by designing a standardized panel and structural component system that serves multiple vehicle length configurations. The same basic panels, shear plates, and framing elements can be used across different vehicle lengths, making the manufacturing system versatile and cost-effective for producing various body sizes.
3Object-affected harmful factors
If fiber-reinforced plastic sheets are used, then corrosion resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies homogeneity by using consistent fiber-reinforced plastic sheeting throughout the vehicle body construction. The same material specifications, fiber orientations, and resin systems are used across all panels, simplifying the manufacturing process while maintaining uniform corrosion resistance. This standardized approach reduces complexity compared to using different materials for different body sections.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The shear panel reduces material content and labor costs, enhances durability, and allows for adaptable vehicle designs by consolidating parts and reducing corrosion risks, while maintaining structural integrity and weight savings.
Implementation Method 1
each of the first and second sheets being formed of a fiber reinforced material so as to provide strength against tension
Implementation Method 2
the core material having a thickness so as to hold the first and second sheets spaced by a distance to provide a resistance of the panel to bending
Data Source
AI summary
A structural shear panel for forming a floor panel for support by a vehicle frame is formed by a composite of top and bottom sheets and a core with a vacuum infused resin. The panel is mainly planar and terminates at its side edges at a portion which lies in a common plane and portions are provided which are deformed out of the generally planar shape to form depending or elevated sections. The structure is formed on a generally flat plate defining the planar panel portion with removable sections to define the depending and elevated sections. Edge pieces are attached to the plate to define the edges of the panel. Accessories are attached to the panel without compressing the core by a base plate of the accessory which is bolted to a bracket which has a backer plate and collar through a hole in the panel.